Films comprising a liquid-absorbant inner layer and an impermeable outer layer

ABSTRACT

Films comprising a liquid-absorbant layer and an impermeable layer are provided. Processes for manufacturing these films is also provided. The films are suitable for preparation of tubular casings and shrinkbags, in particular, casings for smoked foodstuffs. Also described are foodstuffs processed in the tubular casings.

This application is a division of U.S. patent application Ser. No.10/704,934, filed Nov. 11, 2003, now U.S. Pat. No. 7,615,270, whichclaims priority from U.S. Provisional Application No. 60/425,604, filedNov. 12, 2002, now expired, the entire contents being incorporatedherein by reference.

FIELD OF THE INVENTION

This invention relates to a laminate film useful in packaging and/or forencasing foodstuffs. In particular, this invention is a film that isuseful for making casings and shrinkbags that can be used to incorporateadditives into foodstuffs.

BACKGROUND DISCUSSION AND RELATED ART

Generally, foodstuff casings are made either of natural material such ascellulose or animal guts, or of synthetic material. Usually, thefoodstuff is packed into the casing. When smoked products are desired,the encased foodstuff can be further subjected to a smoking process. Ina conventional smoking process, the product is suspended in a chamberwherein it is exposed to hot smoke from burning wood. This process hasthe disadvantage that only natural casings can be used in this process,that is, those obtained from guts, for example, or cellulose or collagencasings which all show a natural permeability to smoke.

A critical point in the preparation and storage of smoked products isthat the casings must show different permeabilities depending on thestep of the process. A high permeability is needed at high temperatures(typically between 50 and 100° C.) and high humidity, during the smokingprocess. Typically, the highly permeable cellulose casings and fibrouscasings (which are cellulose casings reinforced with wood fibers) havemoisture vapor transmission rates in excess of 1000 g·25 micron/m²·24hrs. Once the product is smoked and cooled, it is preferable that thecasing acts as a barrier against humidity so the permeability shouldpreferably be low, that is at rates below 1000 g·25 micron/m² ·24 hrs,at temperatures less than 50° C., particularly less than 30° C.Depending on the specific application, the desired permeability attemperatures less than 30° C. could be substantially below 1000 g·25micron/m² ·24 hrs.

Casings made from natural products and/or cellulose can present manydisadvantages: they can be expensive; their great permeability to steamcan cause significant weight loss from a foodstuff; the product can beunstable due to drying and/or superficial fat oxidation. Also, grayingcaused by microbial spoiling of the natural casing often appears oncasings. The manufacturing process for fibrous and cellulose casingsinvolves emissions of carbon disulfide and hydrogen sulfide to theatmosphere, which can be an environmental concern, or require expensivegas scrubbing systems to minimize emissions.

There have been different approaches which attempt to overcome theseproblems. Single and multilayer plastic casings for packaging sausagesare known in the art, for example. Recently, developments have beendescribed in PCT Patent Application Publication WO 02/054878 to makepolyamide-based casings more smokeable by blending in absorptivepolymers.

Traditional smoking processes also can be inefficient in the absorptionof the smoke flavorants and coloring relative to the amount of smokeproduced in the smoking chamber. To try to overcome the disadvantages ofthe traditional smoking processes, smoke can be passed through water toprepare a concentrated solution of flavorants and colorants absorbedfrom the smoke, and such a solution can be used as a food processingmaterial. This “liquid smoke” can be applied to the foodstuff during thecuring process to flavor and color the foodstuff. Typically liquid smokeis applied to the surface of the food product by showering, atomizing orspraying. However, unless the liquid smoke is maintained in good contactwith the surface of the foodstuff during the cooking process, use ofliquid smoke is still relatively inefficient—more liquid smoke is lostthan is applied. In addition, liquid smokes tend to be corrosive, and ifnot applied properly, cause inconsistent color and flavor.

A commercial practice for using liquid smoke involves laminating aspecial paper product onto a cast multilayer film of polyethylene andpolyamide, and then converting the film into a tubular casing with aspecial sealing strip at the seam. Liquid smoke is then applied to thepaper layer for transfer to the foodstuff during the cooking process.

U.S. Pat. No. 5,382,391 describes a thermoplastic film containing amodifier, such as liquid smoke, which can be transferred to the outersurface of meat during cooking. The inner layer of the thermoplasticfilm is a nonabsorbent polyolefin polymer such as an ethylene vinylacetate copolymer or polyethylene in which is blended with 15 to 40 wt %polyethylene oxide.

U.S. Pat. No. 5,382,391 describes an edible collagen food wrappingcontaining liquid smoke encapsulated within an ingestible lipid or otheroil-soluble fatty acids or waxes, where the liquid smoke is releasedduring curing or cooking, and prior to consumption of thecollagen-enclosed food product.

However, none of the conventional processes are trouble-free. It can bedesirable to have a synthetic casing that can be used effectively andefficiently for storage and for a smoking process utilizing liquidsmoke.

SUMMARY OF THE INVENTION

In one aspect, the present invention is a laminate film comprising (i) aliquid absorptive inner layer useful for imparting flavor and colorevenly to meat during cooking, and (ii) an outer impermeable barrierlayer wherein:

(A) the inner layer comprises a polymer selected from: block copolyetherester polymers or block copolyether amide polymers; and

(B) the outer impermeable film layer is a single film layer, or alaminate or multilayer film comprising: (a) at least one polymer layercomprising a polymer selected from polymers in the group consisting of:polyamides or mixtures thereof, ethylene vinyl alcohol copolymers;polyvinylidene chloride; polyolefins; or mixtures of any of these; and(b) optionally at least one tie layer.

In another aspect, the present invention is a tubular casing or bagcomprising a laminate film comprising (i) a liquid absorptive innerlayer useful for imparting flavor and color evenly to meat duringcooking, and (ii) an outer impermeable barrier layer wherein:

(A) the inner layer comprises a polymer selected from: block copolyetherester polymers or block copolyether amide polymers; and

(B) the outer impermeable film layer is a single film layer, or alaminate or multilayer film comprising: (a) at least one polymer layercomprising a polymer selected from polymers in the group consisting of:polyamides or mixtures thereof, ethylene vinyl alcohol copolymers;polyvinylidene chloride; polyolefins; or mixtures of any of these; and(b) optionally at least one tie layer.

In another aspect, the present invention is a process for making alaminate film of the present invention comprising the step: coextrudingthe impermeable layer and the absorptive layer into a tubular laminatefilm in one step.

In still another aspect, the present invention is a process formanufacturing a film of the present invention by (1) a blowing processor (2) a cast coextrusion process or (3) a coextrusion coating process.

In another aspect, the present invention is a foodstuff prepared using afilm of the present invention.

In still another aspect, the present invention is a process formanufacturing an oriented film of the present invention.

In yet another aspect, the present invention is a package for foodstuffswherein the package absorbs moisture from the foodstuff, while retainingmoisture within the packaging.

DETAILED DESCRIPTION OF THE INVENTION

All references disclosed here in the Detailed Description of theInvention are incorporated by reference, unless stated otherwise.

“Copolymer” means polymers containing two or more different monomers.The terms “dipolymer” and “terpolymer” mean polymers containing only twoand three different monomers respectively. The phrase “copolymer ofvarious monomers” means a copolymer whose units are derived from thevarious monomers.

In one embodiment, the present invention is a laminate film comprisingan absorptive inner layer and an outer barrier layer. As the term isused herein, an inner layer can be any layer other than the outerbarrier layer. For example, an inner layer can be innermost layer, thatis, the layer that can come into direct contact with foodstuff placedinside a casing, or an absorptive inner layer can be any layerpositioned between the innermost layer and the outer barrier layer. Theouter barrier layer is the film layer furthest removed from thefoodstuff.

Polymers suitable for use in an absorptive layer of the presentinvention are characterized by the fact that they are hydrophilic andhygroscopic. The absorptive inner layer comprises a polymer selectedfrom polymers in the group consisting of: block copolyether esterpolymers; and block copolyether amide polymers.

A copolyether ester (PEPE) suitable for use herein is a thermoplasticpolymer. PEPE's suitable for use in the practice of the presentinvention have a viscosity that is in the range of from about 20 pascalseconds (Pa·s) to about 3000 Pa·s as determined according to standardmethod ISO11443. Preferably, the viscosity is in the range from about 20to about 2000 Pa·s, more preferably from about 40 to about 1000 Pa·s,and most preferably from about 50 to about 700 Pa·s, measured accordingto the standard ISO11443.

Preferably, the melting point of the copolyether ester is greater than120° C., more preferably in the range of from about 120° C. to aboveabout 220° C. Melting points are determined by differential scanningcalorimetry (DSC) in accordance with the standard ISO 3146.

Copolyether esters suitable for use herein are described in U.S. Pat.No. 4,725,481, the disclosure of which is incorporated herein byreference. Preferably, the copolyether esters have a multiplicity ofrepeating long-chain ester units and short-chain ester units that arerandomly joined through head-to-tail ester linkages. The repeatinglong-chain ester units can be represented by the formula (I):

and said repeating short-chain ester units can be represented by theformula wherein:

denotes the remaining unspecified portion of the copolyether esterpolymer;

G is a divalent radical remaining after removal of terminal hydroxylgroups from a poly(alkylene oxide) glycol having a molecular weight inthe range of from about 400 to about 3500, preferably from about 1000 toabout 2500; short chain ester unit (II) is the reaction product obtainedfrom an esterification reaction between a diol and a dicarboxylic acid;

-   D is a divalent radical remaining after removal of hydroxyl groups    from a diol having a molecular weight of less than about 250; and-   R is a divalent radical remaining after removal of both carboxylic    acid groups from a dicarboxylic acid having a molecular weight less    than about 300; with the proviso that an ester unit, if it is not a    terminal ester unit, can be bonded at both ends to long chain ester    units, or at both ends to short chain ester units, or at one end to    a long chain ester unit and at the other end to a short chain ester    unit, and with the further proviso that if the ester unit is a    terminal unit, one of the unspecified portions in Formula I or    Formula II is a substituent other than a long chain ester unit or a    short chain ester unit. As used herein, the term “terminal” as it is    used to refer to an ester unit has the meaning that is conventional    in the polymer art, that is, referring to an ester unit located at    the end of a polymeric chain.-   PEPE's of the present invention have a moisture vapor transmission    rate of at least about 1200, preferably from about 1200 to about    20000, g·25 micron/m²·24 hrs as determined according to ASTM    D6701-01.

Poly(alkylene oxide)glycols used to prepare copolyetheresters of thepresent invention preferably comprise poly(propylene ether) glycolsand/or poly(ethylene ether) glycols. Most preferably, ethylene oxidegroups are incorporated into the copolyether esters of the presentinvention. Long chain glycols (that is, glycols having a molecularweight of greater than 400) useful for preparing the copolyether estersof present invention preferably comprise sufficient ethylene oxide sothat the copolyether ester incorporates from about 5 wt % to about 68 wt% ethylene oxide units, preferably from about 15 wt % to about 68 wt %,more preferably from about 20 wt % to about 55 wt % ethylene oxideunits, based on the total weight of the copolyether ester. Reference toethylene oxide groups incorporated in the copolyether ester(s) describesthe weight percent in the total copolyether ester(s) of (—CH₂—CH₂—O—)groups in the long-chain ester units. The ethylene oxide groups in thecopolyether ester that are counted to determine the amount of ethyleneoxide groups in the polymer are those derived from the poly(alkyleneoxide)glycol and not ethylene oxide groups introduced into thecopolyether ester by means of a low molecular weight diol.

Suitable long-chain glycols include poly(ethylene oxide) glycol,ethylene-oxide capped poly(propylene oxide) glycol, mixtures ofpoly(ethylene oxide)glycol with other glycols such as ethylene oxidecapped poly(propylene oxide)glycols and/or poly(tetramethyleneoxide)glycol provided the resulting copolyether ester has an amount ofethylene oxide groups of at least about 5 weight percent. PEPEs preparedfrom poly(ethylene oxide)glycols having a molecular weight of from about600 to 2500 are preferred. Particularly preferred are PEPEs preparedfrom an ethylene oxide capped poly(propylene oxide) having a molecularweight of about 2150.

Suitable low molecular weight diols useful for the purposes of thepresent invention include acyclic, alicyclic and aromatic diols.Preferred are diols having 2-15 carbon atoms such as ethylene glycol,propylene glycol, isobutylene glycol, butylene glycol,1,4-pentamethylene glycol, 2,2-dimethyl-trimethylene glycol, anddecamethylene glycols, dihydroxycyclohexane, cyclohexane dimethanol,resorcinol, hydroquinone, 1,5-dihydroxynaphthalene, and similar diols.Especially preferred are aliphatic diols containing 2-8 carbon atoms,most especially 1,4-butanediol. Bisphenols that are useful includebis(p-hydroxy)diphenyl, bis(p-hydroxyphenyl)methane, andbis(p-hydroxyphenyl)propane. Equivalent ester-forming derivatives ofdiols can also be useful. For example, ethylene oxide or ethylenecarbonate can be used in place of ethylene glycol in the practice of thepresent invention. The low molecular weight diols useful in the practiceof the present invention to include equivalent ester-forming derivativesprovided, however, that the molecular weight requirement pertains to thediol and not to its derivatives.

Dicarboxylic acids useful for making the copolyether esters of thepresent invention are aliphatic, cycloaliphatic or aromatic dicarboxylicacids, and functional equivalents thereof. These equivalents includeesters and ester-forming derivatives, such as acid halides andanhydrides. The molecular weight requirement pertains to the acid formand not to its equivalent ester or ester-forming derivative.

The term “aliphatic dicarboxylic acids”, as used herein, meanscarboxylic acids having two carboxyl groups each attached to a saturatedcarbon atom. If the carbon atom to which the carboxyl group is attachedis saturated and is in a ring, the acid is cycloaliphatic. Aliphatic orcycloaliphatic acids having conjugated unsaturation often cannot be usedbecause of homopolymerization. However, some unsaturated acids, such asmaleic acid, can be used.

Aromatic dicarboxylic acids, as the term is used herein, aredicarboxylic acids having two carboxyl groups attached to a carbon atomin a carbocyclic aromatic ring structure. It is not necessary that bothfunctional carboxyl groups be attached to the same aromatic ring andwhere more than one ring is present, they can be joined by aliphatic oraromatic divalent radicals or divalent radicals such as —O— or —SO₂—.

Representative aliphatic and cycloaliphatic acids which can be usedinclude sebacic acid, 1,3-cyclohexane dicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, adipic acid, glutaric acid,4-cyclohexane-1,2-dicarboxylic acid, 2-ethylsuberic acid,cyclopentanedicarboxylic acid, decahydro-1,5-naphthylene dicarboxylicacid, 4,4,′-bicyclohexyl dicarboxylic acid, decahydro-2,6-naphthylenedicarboxylic acid, 4,4′-methylenebis(cyclohexyl)carboxylic acid and3,4-furan dicarboxylic acid. Preferred acids are cyclohexanedicarboxylic acids and adipic acid.

Representative aromatic dicarboxylic acids include phthalic,terephthalic and isophthalic acids, bibenzoic acid, substituteddicarboxy compounds with two benzene nuclei such asbis(p-carboxyphenyl)methane, p-oxy-1,5-naphthalene dicarboxylic acid,2,6-naphthalene dicarboxylic acid, 2,7-naphthalene dicarboxylic acid,4,4,′-sulfonyl dibenzoic acid and C₁-C₁₂ alkyl and ring substitutionderivatives thereof, such as halo, alkoxy, and aryl derivatives.Hydroxyl acids such as p-(beta-hydroxyethoxy)benzoic acid can also beused providing an aromatic dicarboxylic acid is also present.

Aromatic dicarboxylic acids are a preferred class for preparing thecopolyether ester polymers useful for this invention. Among the aromaticacids, those with 8-16 carbon atoms are preferred, particularlyterephthalic acid alone or with a mixture of phthalic and/or isophthalicacids.

The copolyether esters contain about 25 wt % to about 80 wt %short-chain ester units corresponding to Formula (II) above, theremainder being long-chain ester units corresponding to Formula (I)above. When the copolyether esters contain less than about 25 wt %short-chain ester units, then the crystallization rate becomes very slowand the copolyether ester is tacky and difficult to handle. When morethan about 80 wt % short-chain ester units are present, then thecopolyether esters generally become too stiff. The copolyether esterspreferably contain about 30 wt % to about 60 wt %, more preferably about40 wt % to about 60 wt % short-chain ester units, the remainder beinglong-chain ester units. In general, as the percentage of short-chainester units in the copolyether ester are increased, the polymer has ahigher tensile strength and modulus, and the moisture vapor transmissionrate decreases. Most preferably, at least about 70% of the groupsrepresented by R in Formulae (I) and (II) above are 1,4-phenyleneradicals and at least about 70% of the groups represented by D inFormula (II) above are 1,4-butylene radicals and the sum of thepercentages of R groups which are not 1,4-phenylene radicals and Dgroups which are not 1,4-butylene radicals does not exceed 30%. If asecond dicarboxylic acid is used to make the copolyether ester,isophthalic acid is the acid of choice and if a second low molecularweight diol is used, 1,4-butenediol or hexamethylene glycol are thediols of choice.

It is understood that blends of different copolyether ester polymers areincluded in this invention.

Other minor components may be added as an option to optimize thereaction process or the performance of the copolyether esters obtained.

Block copolyether esters and their preparation are described inEncyclopedia of Polymer Science and Engineering, Volume 12, pages 76-177(1985) and the references reported therein.

Suitable block copolyether esters for use in the present invention areproducts commercially available from a number of companies under varioustradenames, for example Hytrel® available from E.I. du Pont de Nemoursand Company, Riteflex® available from Ticona, and Arnitel® availablefrom DSM.

The absorptive layer in the film of the invention may also compriseblock copolyetheramides. Such block copolyetheramides typically consistof crystalline polyamide and noncrystalline polyether blocks. Typicalpolyamides may be nylon 6 or nylon 12, but the invention is not limitedto copolyetheramides made with these polyamides. A commerciallyavailable series of polyetheramides are available under the tradename“Pebax®” from Atofina.

The Impermeable Outer Layer(s)

A second essential component of the film of the present invention is animpermeable outer layer. An impermeable layer of the present inventioncan be a single film layer, a laminate or multilayer film whichcomprises at least one layer of film comprising a polymer selected frompolymers in the group consisting of: polyamides; ethylene vinyl alcoholcopolymers; polyvinylidene chloride; and polyolefins. The impermeableouter layer can optionally comprise an adhesive layer which is useful asa tie layer between two non-compatible layers in a laminate outer layer.The adhesive layer (tie layer) can comprise anhydride-modified ethylenehomopolymers and/or anhydride-modified ethylene copolymers.

The impermeable barrier structure can comprise several layers ofpolymers to provide effective barriers to moisture and oxygen and bulkmechanical properties suitable for processing and/or packaging thefoodstuff, such as clarity, toughness and puncture-resistance. Forsmoking and/or cooking processes, shrink properties can be important.Examples of multilayer barrier structures suitable for use in thisinvention include, from outermost layer to innermost layer:polyethylene/tie layer/polyamide; polyethylene/tie layer/polyamide/tielayer/polyethylene; polypropylene/tie layer/polyamide/EVOH/polyamide;polyamide/tie layer/polyethylene; polyamide/tie layer/polyethylene/tielayer/polyamide; polyamide/tielayer/polyamide/EVOH/polyamide. Dependingon the nature of the innermost layer of the impermeable structure, anadditional inner tie layer can be interposed between the impermeablestructure and the absorptive layer to provide a desirable level ofadhesion to the absorptive layer.

Polyamides suitable for use herein include aliphatic polyamides,amorphous polyamides, or mixtures thereof. “Aliphatic polyamides” as theterm is used herein can refer to aliphatic polyamides, aliphaticcopolyamides, and blends or mixtures of these. Preferred aliphaticpolyamides for use in the invention are polyamide 6, polyamide 6.66,blends and mixtures thereof. Polyamides 6.66 are commercially availableunder the tradenames “Ultramid C4” and “Ultramid C35” from BASF, orunder the tradename “Ube5033FXD27” from Ube Industries Ltd. Polyamide 6is commercially available under the tradename Nylon 4.12 from E.I. duPont de Nemours, for example.

In a preferred embodiment of the invention, the aliphatic polyamide hasa viscosity ranging from about 140 to about 270 cubic centimeters pergram (cm³/g) measured according to ISO307 at 0.5% in 96% H₂SO₄.

The film may further comprise other polyamides such as those describedin U.S. Pat. Nos. 5,408,000; 4,174,358; 3,393,210; 2,512,606; 2,312,966and 2,241,322, which are incorporated herein by reference. The film mayalso comprise partially aromatic polyamides. A suitable partiallyaromatic polyamide is the amorphous copolyamide 6-I/6-T of the followingformula:

Some suitable partially aromatic copolyamides for use in the presentinvention are the amorphous nylon resins 6-I/6-T commercially availableunder the tradename Selar® PA from E.I. du Pont de Nemours and Companyor commercially available under the tradename Grivory® G 21 fromEMS-Chemie AG, for example.

Polyolefins suitable for use in the present invention are selected frompolypropylenes, polyethylene polymers and copolymers. Polyethylenesuseful for use herein can be prepared by a variety of methods, includingwell-known Ziegler-Natta catalyst polymerization (see for example U.S.Patent No. 4,076,698 and U.S. Pat. No. 3,645,992), metallocene catalystpolymerization (see for example U.S. Pat. No. 5,198,401 and U.S. Pat.No. 5,405,922) and by free radical polymerization. Polyethylene polymersuseful herein can include linear polyethylenes such as high densitypolyethylene (HDPE), linear low density polyethylene (LLDPE), very lowor ultralow density polyethylenes (VLDPE or ULDPE) and branchedpolyethylenes such as low density polyethylene (LDPE). The densitiespolyethylenes suitable for use in the present invention range from 0.865g/cc to 0.970 g/cc. Linear polyethylenes for use herein can incorporatealpha-olefin comonomers such as butene, hexene or octene to decreasetheir density within the density range so described. The impermeablelayer of the present invention can comprise ethylene copolymers such asethylene vinyl esters, ethylene alkyl acrylates, ethylene aciddipolymers, ethylene acid terpolymers and their ionomers. Examples ofsuch ethylene copolymers are ethylene vinyl acetate, ethylene methylacrylate and ethylene (meth)acrylic acid polymers and their ionomers.Polypropylene polymers useful in the practice of the present inventioninclude propylene homopolymers, impact modified polypropylene andcopolymers of propylene and alpha-olefins and their blends.

Polyethylene/vinyl alcohol copolymers (“EVOH”) having from about 20 toabout 50 mole % ethylene can be suitable for use herein. Suitablepolyethylene vinyl alcohol copolymers are commercially available underthe tradename Evalca® from Kuraray or commercially available under thetradename Noltex® from Nippon Goshei, for example.

Polyvinylidene chloride (PVDC) suitable for use herein can be obtainedcommercially from Dow Chemical under the tradename Saran®, for example.

Anhydride or acid-modified ethylene and propylene homo- and co-polymersare used as extrudable adhesive layers (also known as “tie” layers) toimprove bonding of layers of polymers together when the polymers do notadhere well to each other, thus improving the layer-to-layer adhesion ina multilayer structure. The compositions of the tie layers can bedetermined according to the compositions of the adjoining layers thatneed to be bonded in a multilayer structure. One skilled in the polymerart can select the appropriate tie layer based on the other materialsused in the structure. Various tie layer compositions are commerciallyavailable under the tradename Bynel® from E.I. du Pont de Nemours andCompany, for example.

Impermeable films of the present invention can additionally compriseoptional materials, such as the conventional additives used in polymerfilms including: plasticizers, stabilizers, antioxidants, ultravioletray absorbers, hydrolytic stabilizers, anti-static agents, dyes orpigments, fillers, fire-retardants, lubricants, reinforcing agents suchas glass fiber and flakes, processing aids, antiblock agents, releaseagents, and/or mixtures thereof.

Polymers described herein can be converted into a laminate film of thepresent invention by various techniques. For example, a laminate filmcan be obtained by coextrusion as follows: granulates of the variouscomponents can be melted in extruders; the molten polymers passedthrough a die or set of dies to form layers of molten polymers that arethen processed as a laminar flow. The molten polymers can be cooled toform a layered structure. A coextruded polymer of the present inventioncan be laminated onto one or more other layers.

Other suitable converting techniques are, for example, blown filmextrusion, cast film extrusion, cast sheet extrusion and extrusioncoating. Preferably, the impermeable barrier film of the presentinvention is a blown film obtained by a blown film extrusion process.

A laminate film of the present invention can be further oriented beyondthe immediate quenching or casting of the film. The process comprisesthe steps of coextruding a multilayer laminar flow of molten polymers,quenching the coextrudate and orienting the well quenched coextrudate inat least one direction. “Well-quenched” as the term is used hereindescribes an extrudate that has been substantially cooled below itsmelting point in order to obtain a solid film material.

The film may be uniaxially oriented, but is preferably biaxiallyoriented by drawing in two mutually perpendicular directions in theplane of the film to achieve a satisfactory combination of mechanicaland physical properties.

Orientation and stretching apparatus to uniaxially or biaxially stretchfilm are known in the art and may be adapted by those skilled in the artto produce films of the present invention. Examples of such apparatusand processes include, for example, those disclosed in U.S. Patent Nos.3,278,663; 3,337,665; 3,456,044; 4,590,106; 4,760,116; 4,769,421;4,797,235 and 4,886,634.

In a preferred embodiment of the present invention, the laminate film ofthe present invention is oriented using a double bubble extrusionprocess, where simultaneous biaxial orientation may be effected byextruding a primary tube which is subsequently quenched, reheated andthen expanded by internal gas pressure to induce transverse orientation,and drawn by differential speed nip or conveying rollers at a rate whichwill induce longitudinal orientation.

The processing to obtain an oriented blown film is known in the art as adouble bubble technique, and can be carried out as described by Pahlkein U.S. Pat. No. 3,456,044. More particularly, a primary tube is meltextruded from an annular die. This extruded primary tube is cooledquickly to minimize crystallization. It is then heated to itsorientation temperature (for example, by means of a water bath). In theorientation zone of the film fabrication unit a secondary tube is formedby inflation, thereby the film is radially expanded in the transversedirection and pulled or stretched in the machine direction at atemperature such that expansion occurs in both directions, preferablysimultaneously; the expansion of the tubing being accompanied by asharp, sudden reduction of thickness at the draw point. The tubular filmis then again flattened through nip rolls. The film can be reinflatedand passed through an annealing step (thermofixation), during which stepit is heated once more to adjust the shrink properties. For preparationof food casings (for example, sausage casings, shrink bags) it may bedesirable to maintain the film in a tubular form. For preparing flatfilms the tubular film can be slit along its length and opened up intoflat sheets that can be rolled and/or further processed.

In another embodiment, the present invention is a process ofmanufacturing an oriented flat film comprising the steps of: 1)coextruding or coextrusion laminating an multilayer extrudate comprisingan absorptive inner layer of the present invention and an impermeableouter layer of the present invention; and 2) processing the compositionof step 1) through a flat die to form a well-quenched primary sheet andthen orienting the sheet by means of a tenterframe stretcher, throughtraverse of a widening frame for transverse direction orientation andoperation of differential speed nip or conveying rollers for machinedirection orientation; both steps may occur either simultaneously orsequentially.

In still another aspect of the present invention is a process formanufacturing a tubular film comprising the steps of: (1) coextruding amultilayer extrudate comprising an absorptive inner layer of the presentinvention; (2) processing the extrudate of step (1) through an annulardie to form a bubble film that is quenched by air or other means ofinternal bubble cooling and subsequently collapsed to make the tubularfilm.

In yet another aspect, the present invention is a process ofmanufacturing a cast flat film comprising the steps of: 1) coextrudingor coextrusion laminating an multilayer extrudate comprising anabsorptive inner layer of the present invention and an impermeable outerlayer of the present invention; and 2) processing the composition ofstep 1) through a flat die onto a chilled metal roll to form a flexiblelaminate film.

The oriented flat film, the cast flat film or the tubular film slit toopen it into a flat film may be further laminated to another filmsubstrate by laminating methods known in the art, such as aqueouslamination, solvent lamination, solventless lamination, and the like.

In one embodiment, the absorptive inner layer with an optional tielayer, can be extrusion-coated onto a preformed barrier structure toform a film of this invention.

Preferably, the film of the invention can be processed on a filmfabrication machine at a speed of from about 50 meters per minute(m/min) to a speed of about 200 m/min.

Films of the present invention can be useful for encasing and processingfoodstuffs. Typically, the films are made into tubular casings, eitherby using blown film techniques to prepare a tubular form directly or byforming a flat sheet of the film into a tubular structure and fasteningthe edges of the sheet in a seam running the length of the tube. Tofacilitate the introduction of the foodstuff into the interior of thetubular casing, the casing optionally may be shirred prior to theintroduction of the foodstuff. The term “shirred” means that the tubularcasing is gathered into a multiplicity of rows parallel to thecircumference of the tubing. The foodstuff is introduced into theinterior of the optionally shirred tubular casing via the open end andthe tube is stretched out to encase the foodstuff. One skilled in theart of packaging foodstuffs can readily introduce the foodstuff into thecasing using well-established procedures.

The tubular casing can be further treated by the adsorption of at leastone liquid food-processing flavorant and/or colorant into the absorbantlayer of the casing. The flavorant and/or colorant is subsequentlytransferred to the foodstuff during such food processing as heating,curing, smoking, or cooking, for example.

In a preferred embodiment, a tubular casing of this invention comprises“liquid smoke” as a food-processing material which acts as both aflavorant and a colorant. Liquid smoke is well known to one skilled inthe art of food processing and numerous variants are known andcommercially available. Preferably a tubular casing comprising liquidsmoke can be useful for processing sausage.

Foodstuffs that can be processed using film of this invention includebeef, pork, poultry (for example, chicken and turkey), seafood (forexample, fish and mollusks) and cheese. Meat products include, but arenot limited to sausages, lunch meats, hams, turkey, hot dogs, kielbasa.Meat products can be whole-muscle, formulated into various meatslurries, formed into shapes, or ground. In the case of formed or groundmeat, the meat can optionally be a mixture of material derived from morethan one species. The foodstuff can be processed prior to itsintroduction into a casing of the present invention and then furtherprocessed in the casing.

In another embodiment, films of the present invention can also be madeinto bags, such as vacuum bags, shrinkbags, and pouches. Such bags canbe formed form tubular film by sealing and then cutting the filmtransversely. Alternatively, the tubular film may be slit into flatfilm, and then sealed transversely at the top and bottom to producebags. Alternatively, flat film whether produced by tubular or castprocesses may be made into bags by folding the film and then sealing andcutting along two exposed lengths. Other methods of making bags andpouches are known and can be also used for the films of this invention.

In another embodiment, films of the present invention can be used forpackaging foodstuffs where it is desirable to have absorption ofmoisture from the foodstuff, while retaining moisture within thepackaging. Films of this invention can be used, for example, to packageuncooked meat or cooked meats (e.g. beef, pork, poultry or seafood)wherein moisture from the foodstuff or excess marinades on the foodstuffcan pass out of the foodstuff and pool below. Such films may be on theform of pouches, bags, casings or thermoformed films. It is also withinthe invention that the films of the invention may be laminated ontoother substrates before being thermoformed.

The following table describes examples and comparative examples of thecompositions of the absorptive layer. Examples are merely illustrative,and are not to be construed as limiting to the scope of the inventiondescribed and/or claimed herein.

TABLE 1 Melt Point Example Polymer Type ° C. Description 1 Copolyetherester 200 45 w % 1,4-butylene terephthalate, 55 w % ethyleneoxide/propylene oxide copolyether terephthalate. Calculated ethyleneoxide content of 33%. 2 Copolyether ester 170 42 w % 1,4-butyleneterephthalate, 12 w % 1,4- butylene isophthalate, 36 w % ethyleneoxide/propylene oxide copolyether terephthalate, 10 w % ethyleneoxide/propylene oxide copolyether isophterephthalate. Calculatedethylene oxide content of 13%. 3 Copolyether ester 155 32 w %1,4-butylene terephthalate, 9 w % 1,4- butylene isophthalate, 46 w %ethylene oxide/propylene oxide copolyether terephthalate, 13 w %ethylene oxide/propylene oxide copolyether isophterephthalate.Calculated ethylene oxide content of 17%. 4 Copolyester amide 156Pebax ® MV 1074 5 Copolyester amide 195 Pebax ® MH 1657 Comp Ex 1 Nylon6 219 Capron ® B135ZP Comp Ex 2 Nylon 6.66 Ultramid ® C135 Comp Ex 3Copolyester Selar ® PT 8307 Comp Ex 4 Copolyether ester 211 70 w %1,4-butylene terephthalate, 30 w % poly(tetramethylene oxide)terephthalate. Calculated ethylene oxide content of 0%. Comp Ex 5Copolyether ester 203 60 w % 1,4-butylene terephthalate, 40 w %poly(tetramethylene oxide) terephthalate. Calculated ethylene oxidecontent of 0%.

The polymers of Table 1 were coextruded with other non-adhering polymerson a three-layer blown film line in order to generate three-layer filmsin which the absorptive layer of the film could be easily removed. Inall cases, either HDPE (high density polyethylene) or nylon 6 were theother layers coextruded against the polymers of Table 1. In a number ofcases, an antiblock concentrate sold by DuPont as Conpol® AC B was alsoadded as described in the cases below. Blow up ratio was 2:1, and thestripped film layers had various thicknesses ranging from 25 to 64microns.

In order to determine moisture pickup after 24 hours, the coextrudedfilms were cut into 15.24 cm by 15.24 cm (6×6 inches) squares and thenstripped. The absorptive film layer was then conditioned at 23° C. and20% relative humidity for at least 24 hours before being weighed andthen placed in a container of water. After 24 hours, the films weretaken out, patted dry with paper towels so that no free moisture wasvisible on the film surfaces, and then immediately weighed. For eachexample in Table 2, the average taken of three samples is reported asthe weight percent moisture absorption. The films conditioned at 23° C.and 20% relative humidity for at least 24 hours were also measured formoisture vapour transmission rate (MVTR) at 38° C. and 100% relativehumidity. For samples with high water permeability, the transmissiontests were conducted on a Mocon Permatran-W® 101K, following ASTMD6701-01. For the other samples, the transmission tests were conductedon a Mocon Permatran-W® 700, following ASTM F1249-01.

TABLE 2 24 Hour Film Water Gauge Gain MVTR Example Polymer Type micronsw % g-25 micron/m²-day 1 Copolyether ester 1 30 23.9 14463 1 Copolyetherester 1 53 24.0 16635 1 Copolyether ester 1 64 24.1 14109 2 Copolyetherester 2 48 2.1 2261 3 Copolyether ester 3 41 5.9 5115 4 Copolyesteramide 1 43 29.8 10698 5 Copolyester amide 2 43 60.6 13106 Comp 1 Nylon 620 7.6 651 Comp 2 Nylon 6.66 22 8.2 809 Comp 3 Copolyester 25 1.1 169Comp 4 Copolyether ester 4 46 0.7 762 Comp 5 Copolyether ester 5 46 0.1822 Note: Examples 1, 2 and 3 and Comparative Examples 4 and 5 alsocontained 2 weight % antiblock, Conpol ® AC B.

The examples in Table 2 have both high moisture absorption as well ashigh moisture transmission, whereas the comparative examples either showeither poor moisture absorption and poor transmission or good moistureabsorption but poor transmission.

Moisture pickup as a function of time up to 24 hours was also recorded.The films were subjected to the same treatment as described for Table 2.After each time of exposure in water, the films were taken out, patteddry with paper towels so that no free moisture was visible on the filmsurfaces, and then immediately weighed. These films were then discarded,and a different set of films used to measure the water pick up for adifferent exposure time. For each example and time in Table 3, theaverage measured for three samples is reported as the weight percentmoisture absorption.

TABLE 3 Water Absorption (wt % gain) at 23° C. over Time Gauge Examplemicrons 0 hr 0.5 hr 1 hr 3 hr 5 hr 7 hr 24 hr 1^(a) 53 0 18.2 ± 6.0 23.6± 5.0  22.7 ± 0.5  21.1 ± 0.8  24.2 ± 0.4 24.0 ± 1.4 1^(b) 53 0 16.0 ±15  23.2 ± 16   21.8 ± 0.8  19.9 ± 1.4  23.0 ± 1.2 23.8 ± 0.5 2^(a) 48 0 2.4 ± 0.2 2.6 ± 0.3 2.1 ± 0.3 2.4 ± 0.1  2.7 ± 0.2 2.07 ± 0.2 3^(a) 640 7.4 ± 4  3.8 ± 4.3 6.9 ± 1.0 4.2 ± 0.4 5.41 ± 1.6  5.9 ± 0.4 Comp5^(a) 43 0  0.6 ± 0.8 1.4 ± 1.6 0.4 ± 0.2 2.7 ± 3.4  0.2 ± 0.1  0.1 ±0.1 Comp 2 22 0 10.1 ± 0.1 8.6 ± 1.8 7.9 ± 0.7 8.6 ± 0.8  7.0 ± 0.8  8.2± 1.0 Notes: ^(a)Examples 1, 2, 3 and Comparative Example 5 alsocontained 2 weight % antiblock, Conpol ® AC. ^(b)Example 1 alsocontained 15 weight % antiblock, Conpol AC B.

This table show that water pick up occurs quickly for both examples andcomparative examples. Within 0.5 hours, the examples are close to orabout the equilibrium level of water pickup at 23° C.

Moisture release from the films as a function of time and temperaturewas also recorded. In these experiments, the films were conditioned to23° C. at 20% relative humidity for at least 24 hours, weighed to recordits ‘dry’ weight, then placed in water at 23° C. for at least 24 hours(in some cases for 2 to 3 days) taken out, patted dry with paper towelsso that no free moisture was visible on the film surfaces, andimmediately weighed for its water-absorbed weight. Immediately afterbeing weighed, the films were suspended in a radiant heat oven set at90° C. No more than three films were placed in the oven at any one time,so that the individual films did not touch each other or the sides ofthe oven wall. The films were then taken out at 5, 10 and 60 minutes tobe weighed. The averages of five to eight film samples are reported inTable 4 below.

TABLE 4 W % water pickup after soaking at % Weight Loss^(a) with 23° C.for Time at 90° C. 24 hours or greater 5 mins 10 mins 60 mins EX 1^(b)29.4 ± 3.7  −1.0 ± 1.2 −0.8 ± 1.1 −0.8 ± 1.2 EX 3^(b) 5.4 ± 0.6 −0.8 ±0.2 −0.9 ± 0.2 −0.8 ± 0.2 EX 4 45 ± 1  −0.6 ± 0.4 −0.8 ± 0.3 −0.9 ± 0.3Ex 5 129 ± 9   8.9 ± 5.6 −8.1 ± 0.6 −8.3 ± 0.3 Comp 5^(b) 0.8 ± 1.0 −0.2± 0.2 −0.05 ± 0.2  −0.1 ± 0.2 ^(a)% weight loss from ‘dry’ weight offilm, as decribed in the text. ^(b)Examples contained 2 w % antiblock,Conpol ® AC B.

The results in Table 4 show that the water-absorbed films very quicklyrelease their water content at 90° C. within 5 minutes. Note that inmany cases the weight of the films falls below the original ‘dry’ weightof the films. This is attributed to the fact that the original ‘dry’weight was taken at 20% relative humidity, whereas the films were likelyat a lower relative humidity with the heat treatment.

The next set of tests were conducted to determine the amount of liquidsmoke taken up by the examples and comparative examples. The filmsamples were similar to those described in the earlier sets. The 6 by 6inch stripped films were then placed in a 1 liter Nalgene™ high densitypolyethylene bottle filled with a liquid smoke, Charsol Supreme™ fromRed Arrow Products or worcestershire sauce from Lea & Perrins and screwcapped. Some films had been soaked between one to five days; however, itappeared that color changes owing to the absorption of the liquid mediumwas essentially complete by about 24 hours. The films in Table 5 weresoaked for 48 hours, then were taken out on from the bottle, dried wellwith paper towels, and then placed against a white sheet of paper. Table5 provides a description of the results.

TABLE 5 Film gauge Description of Absorbent microns post-absorbed filmcolour Ex 1 Liquid smoke 53 Very dark brown Ex 1 Liquid smoke 32 Darkbrown Ex 1 Worcestershire 53 Brown sauce Ex 4 Liquid smoke 43 Very darkborwn Comp 2 Liquid smoke 22 Light brown with amber yellow to clearpatches Comp 3 Liquid smoke 30 Transparent, no colour Comp 4 Liquidsmoke 46 Light tan

A clear, transparent multilayer tubular film was produced on a fivelayer double bubble line with the structure, from the outside of thetube to the inside, of Nylon 6 (28μ)/Bynel® 21 E787(3μ)/PE (5μ)/Bynel®21 E787 (5μ)/Example 1 (14μ) with a total gauge of 55 microns (μ). Asection of this film was also placed in a container of liquid smoke for48 hours, removed and dried with paper towels. Upon removal, themultilayer film was brown.

Multilayer films containing the different examples were tested forliquid smoke transfer to meat at typical cooking and smoking conditions.In the first test, sheets of the examples and Comparative Example 6casing materials, approximately 210 mm by 300 mm, were prepared.Comparative Example 6 is a commercially available smoking casingmaterial comprising a multilayer polyethylene (15μ)/tielayer/polyamide(30μ)/tie layer/polyethylene(15μ) coextrudate laminatedonto viscose-coated paper. The examples of the present invention were(co)extruded with different materials as described in Table 6, and werenominally between 25 to 50 microns.

To assess the liquid smoke absorption and transfer to foodstuff (e.g.meat), the casing materials were treated as follows:

liquid smoke was applied to the surface of the test film via aneyedropper and spread over the surface. After approximately 2 minutes,excess liquid smoke on the surface of the material was wiped off. ForComparative Example 6, smoke impregnation was conducted forapproximately two days according to established procedures for thismaterial.

The smoke-impregnated materials were laid over in a baking dish with thesmoke-impregnated layer in contact with a ham product. The test unitswere treated in a typical “smoking” cycle at 180° F. for about two tothree hours.

The smoke color of the ham product, as an indicator of smoke transferfrom the casing material to the foodstuff, was rated on a scale from 1to 5, with 1 indicating minimal smoke color and 5 indicating the mostsmoke color. The results are indicated in Table 6.

TABLE 6 Casing Material Smoke Color Rating Example 2 on Polyethylene 3Example 2 on Paper 4; smoke liquid did not go into paper Example 1 onPolyethylene 5 Comparative Example A 5

In the next test multilayer blown film tubing of approximately 16.5 cmlayflat width (or 10.5 cm in diameter) containing the examples as theinner absorbent layer were pre-absorbed with liquid smoke and allowed todry. The tubing had a three layer structure of nylon 6 (50microns)/Bynel® 21 E787 (18 microns)/absorptive layer (see Table 7). Thetubing was hand stuffed with a ham formulation against the absorptivelayer and then cooked under typical cooking conditions suitable for thespecific meat product. A typical cooking cycle that was used was: 60° C.(dry bulb)/49° C. (wet bulb) for 30 minutes, followed by 68° C. (drybulb)/57° C. (wet bulb) for 30 minutes, followed by 77° C. (drybulb)/77° C. (wet bulb) for 2.5 hours. Table 7 describes the color ofthe meat product on removal of the casing following cooking.

TABLE 7 Absorptive layer gauge microns Smoke transfer to product Ex 1 38Excellent smoked colour Ex 1 51 Excellent smoked colour Ex 2 51 Goodsmoke colour Ex 3 51 Good smoke colour

1. A food package comprising a film laminate comprising (i) a liquid absorptive layer useful for imparting flavor and color evenly to meat, and (ii) an impermeable barrier layer wherein: (A) the liquid absorptive layer comprises a block copolyether ester polymer; and (B) the impermeable barrier layer comprises a structure selected from the group consisting of single film layers, multilayer films and laminates, the barrier layer comprising: (a) at least one layer comprising a polymer, wherein the polymer is selected from the group consisting of: polyamides; mixtures of polyamides; ethylene vinyl alcohol copolymers; polyvinylidene chloride; polyolefins; and mixtures of any of these; and (b) optionally at least one tie layer; and wherein the liquid absorptive layer has a moisture vapor transmission rate of from about 1200 to about 20,000 g 25 micron/m² 24 hrs.
 2. A package of claim 1 wherein the film laminate has been treated with a food-processing material selected from the group consisting of flavorants and colorants.
 3. A package of claim 1 wherein the film laminate has been treated with liquid smoke.
 4. A package of claim 1 wherein the package is in the form of a tubular casing or bag.
 5. A package of claim 4 wherein the package is in the form of a tubular casing.
 6. A package of claim 4 wherein the bag is selected from the group consisting of vacuum bags, shrinkbags, and pouches.
 7. A package of claim 1 wherein the package contains a foodstuff.
 8. A package of claim 7 wherein the foodstuff is selected from the group consisting of beef, pork, poultry, seafood and cheese.
 9. A package of claim 7 wherein the foodstuff is selected from the group consisting of lunch meats, hams, hot dogs and kielbasa.
 10. A package of claim 7 wherein the foodstuff is sausage.
 11. A package of claim 7 wherein the foodstuff is uncooked meat.
 12. A package of claim 7 wherein the foodstuff is cooked meat. 